Reel control systems with data logging

ABSTRACT

An electronic control unit may, based on received sensor data, automatically direct the operation of a reel assembly for deploying a cable, hose or umbilical connection. The electronic control unit may operate in conjunction with an electro-pneumatic drive to control the reel assembly. Sensors may measure various parameters, such as a measured line tension and/or a length of cable, hose or umbilical connection that has been deployed, and transmit the measured data to the electronic control unit. Optionally, the sensor data and/or user control inputs and system status information may be logged. The system also may use this data to control the system, such as by activating an alarm when a certain alarm limit is exceeded by the data, adjusting the pressure or other parameters of the electro-pneumatic drive, and the like. The system also may generate a visual notification for an operator when an alarm is triggered.

This application is a continuation in part of and claims benefit ofpriority from U.S. patent application Ser. No. 14/945,195 filed Nov. 18,2015, which is incorporated by reference in its entirety which isfurther a continuation of U.S. patent application Ser. No. 14/802,814filed Jul. 17, 2015, now U.S. Pat. No. 9,206,658, which is incorporatedby reference in its entirety. This application also claims priority toU.S. Provisional Patent Application No. 62/404,011 filed Oct. 4, 2016,which is incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION 1. Technical Field

The present application relates to reel systems for the receiving,storage, and deploying of cables (such as one or more electrical lines),hoses, umbilical connections (such as bundles of hydraulic lines,electrical lines, cables, hoses, and/or combinations thereof) and thelike that can store operator inputs and collected, real time data.

2. Related Art

Subsea blowout prevention equipment (BOP) uses large, specialized valvesor similar mechanical devices, usually installed redundantly in stacks,to seal, control and monitor oil and gas wells. Redundant sub-seacontrol pods are used to control the valves of the BOP stack, some ofwhich are referred to in the industry as blue and yellow pods. The podsof the BOP stack are controlled by cables, hoses, umbilical connectionsand the like with various capacity outside diameters. The reel systemsused for winding the cable, hoses, umbilical connections and the likeonto spools, particularly on off-shore drill rigs, employ spools whichare mechanically driven.

Off-shore drill rigs often use multiplex cable reels, hot line hosereels, riser fill valve hose reels and the like in control systems forBOP equipment. Each of these components may provide variousfunctionalities. In a typical rig, four spools may provide controlcables for a BOP stack. These components may function as follows:multiplex cable reel assemblies may be used to pay out and retrievemultiplex cables that may be used to transmit electric signals to allowfor the control of sub-sea hydraulic functions on the sub-sea blue andyellow pods; a hot line hose reel assembly may be used to pay out andretrieve a hose that provides hydraulic fluid from the drilling rig deckto the sub-sea pods to allow for the control of sub-sea hydraulicfunctions on the sub-sea blue and yellow pods; and a riser fill valvehose reel assembly may pay out and retrieve a hose that, in response toa sudden pressure differential between the inside and outside of ariser, opens to allow the riser to fill with seawater and thusequalizing the pressure differential and preventing collapse of theriser.

In operation, the spools are typically located on the drillship near amoon pool area (i.e. the opening in the floor or base of the platform toprovide access to the water below) and may be on different levelsdepending on the rig design. The cable or hose often is deployed fromthe spool to an overhead roller type turn down sheave, or multiplesheaves, to direct the cable or hose to the blue and yellow pods on theBOP stack assembly in the drill ship's moon pool.

Typical systems employ manual, pneumatically-controlled, mechanicalcontrol systems for each of the individual reel assemblies, to positionthe sub-sea end of the cable or hose to the pod. Once the cables andhoses are connected to the pods, the operation of deploying the BOPstack begins. Drill pipe and flotation risers having typical lengths of60 to 90 feet or more (nominally, about 18 to 28 meters) are attached tothe stack. The cables and hoses are attached to clamps located on theriser as the 60 or 90 foot (nominally, about 18 to 28 meters) sectionsare made up. The reels are not rotating while the drill pipe and risersections are made up. Once made up, the reels begin rotating to deploythe cables and hoses until the next section is ready to be attached.This operation continues until the BOP stack is anchored to the sea bedfloor. A control stand may be located away from the spools, in the moonpool area, with a clear vision of the deployment. The operator at theremote control stand may be able to operate one or more of the reelassemblies and may make adjustments as may be necessary during theoperation.

Currently, the pneumatically driven mechanical control systems used tocontrol the reel assembly operation suffer from various shortcomings.For example, there are limitations on the locations of reel assembliesand a remote control stand because pneumatic control signals are subjectto decreasing performance such as slower responses as the distancebetween the reel and the remote control stand increases. As anotherexample, mechanical push-pull valves are used to alternate controlbetween a local controller and a remote control stand. The use of thesevalves necessitate that an operator manually activate the valve at eachreel assembly to provide full control of the system to the remotecontrol stand. In addition, current reel assemblies do not provide muchfeedback to the operator about the actual conditions of the cable/hose,such as accurate, measured information about the actual tension on thecable/hose or how much of the cable/hose has been deployed. Current reelassemblies also do not use this type of measured information to controlthe operation of the system.

Small cable and wire spooling devices, such as Warn® winches found oncars, trucks, and small industrial equipment, may use electric controlsystems and electric motors to control the system. These electriccontrol systems also suffer from various shortcomings, particularly forlarge scale applications. For example, a large electric motor demandinghigh electrical power may be needed. Due to this, the motor can bedifficult to control by an operator and difficult to keep cool.Furthermore, manual controls, such as joysticks, only allow for simplefunctions based entirely on input from an operator.

Recently, Congress and Executive Agencies have enacted new laws andpromulgated new regulations regarding offshore subsea oil drilling, inpart a response to a number of oil spills throughout the early 21^(st)century. Some of these new laws and regulations require offshore oildrill operators to maintain records of various parameters and collecteddata during drilling to increase safety and create accountability in theevent of an accident. Furthermore, this data may be able to helpgovernment and private investigations to determine the cause ofaccidents and/or prevent them from occurring in the future.

Finally, current systems attempt to estimate the amount of the deployedcable and/or tension on a given line for cables deployed with the BOPstack. These estimations are unreliable and do not necessarily reflectthe actual tension or length that may be present for a given line.Mistakes can be made because operators are making decisions based onimprecise information.

Accordingly, a need has long existed for improved systems and methodsfor controlling cable spooling systems.

SUMMARY

In certain aspects, an electronic control unit may, based on receivedsensor data, automatically direct the operation of a reel assembly fordeploying a cable, hose or umbilical connection. The electronic controlunit may operate in conjunction with an electro-pneumatic drive tocontrol the reel assembly. Sensors may measure various parameters, suchas a measured line tension and/or a length of cable, hose or umbilicalconnection that has been deployed, and transmit the measured data to theelectronic control unit. Optionally, the sensor data and/or user controlinputs and system status information may be logged. The system also mayuse this data to control the system, such as by activating an alarm whena certain alarm limit is exceeded by the data, adjusting the pressure orother parameters of the electro-pneumatic drive, and the like. Thesystem also may generate a visual notification for an operator when analarm is triggered.

In one aspect, a reel assembly for accepting, holding, and deployingcable, hose, umbilical connections or the like, may include a spoolassembly including a frame and a drum mounted in said frame. The drummay include a core and end flanges for storing said cable, hose orumbilical connection. The reel assembly may also include an air motorand an electro-pneumatic drive unit including a plurality of pneumaticvalves, electro-pneumatic valves, or both, and the air motor may becoupled to the drum via the electro-pneumatic drive unit. The reelassembly may also include an electronic control unit coupled to theelectro-pneumatic drive unit. The electronic control unit may receiveuser input and may transmit electrical signals to the electro-pneumaticdrive unit to cause the electro-pneumatic drive unit to control themotor to rotate the drum. The electronic control unit may also receiveinput and may transmit electrical signals to the electro-pneumatic driveunit to cause the electro-pneumatic drive unit to increase or decreasean air pressure associated with the assembly.

In another aspect, a reel assembly for accepting, holding, and deployingcable, hose, umbilical connections or the like, may include a spoolassembly including a frame and a drum mounted in said frame, and thedrum may include a core and end flanges for storing said cable, hose orumbilical connection. The reel assembly may also include an air motorand an electro-pneumatic drive unit including a plurality of pneumaticvalves, electro-pneumatic valves, or both, and the air motor may becoupled to the drum via the electro-pneumatic drive unit. The reelassembly may also include a local electronic control unit coupled to theelectro-pneumatic drive unit, and the local electronic control unit mayreceive user input and may transmit electrical signals to theelectro-pneumatic drive unit to cause the electro-pneumatic drive unitto control the motor to rotate the drum. The local electronic controlunit may also receive input and may transmit electrical signals to theelectro-pneumatic drive unit to cause the electro-pneumatic drive unitto increase or decrease an air pressure associated with the assembly.The reel assembly may also include a remote electronic control unitcoupled to the electro-pneumatic drive unit, and the remote electroniccontrol unit may receive user input and may transmit electrical signalsto the electro-pneumatic drive unit to cause the electro-pneumatic driveunit to control the motor to rotate the drum. The remote electroniccontrol unit may also receive input and may transmit electrical signalsto the electro-pneumatic drive unit to cause the electro-pneumatic driveunit to increase or decrease an air pressure associated with theassembly.

In yet another aspect, a system for deploying a blowout prevention (BOP)stack may include a plurality of reel assemblies for accepting, holding,and deploying cable, hose, umbilical connections or the like. Each reelassembly may include a spool assembly including a frame and a drummounted in said frame, and the drum may include a core and end flangesfor storing said cable, hose or umbilical connection. Each reel assemblymay also include an air motor and an electro-pneumatic drive unitincluding a plurality of pneumatic valves, electro-pneumatic valves, orboth, and the air motor may be coupled to the drum via theelectro-pneumatic drive unit. Each reel assembly may also include alocal electronic control unit coupled to the electro-pneumatic driveunit, and the local electronic control unit may receive user input andmay transmit electrical signals to the electro-pneumatic drive unit tocause the electro-pneumatic drive unit to control the motor to rotatethe drum. The system may also include a remote electronic control unitcoupled to the electro-pneumatic drive unit of each of the plurality ofreel assemblies, and the remote electronic control may provide userinterface controls for controlling each of the plurality of reelassemblies, may receive user input for controlling a selected reelassembly and, in response, may transmit electrical signals to theelectro-pneumatic drive units of the selected reel assembly to cause theelectro-pneumatic drive unit of the selected reel assembly to controlthe motor of the selected reel assembly to rotate the drum of theselected reel assembly.

In another aspect, a reel assembly may include a local electroniccontrol unit and a remote electronic control unit. Selection of a userinterface control on the remote electronic control unit may cause thelocal electronic control unit to display indicia indicative of at leastone selected from the group of the user's selection on the remoteelectronic control unit user interface control and a current mode ofoperation.

In still another aspect, a reel assembly may include a local electroniccontrol unit and a remote electronic control unit. Selection of a userinterface control on the local electronic control unit may cause theremote electronic control unit to display indicia indicative of at leastone selected from the group of the user's selection on the localelectronic control unit user interface control and a current mode ofoperation.

In other various aspects, a reel assembly may include a sheave coupledto one or more sensors that determine either a force applied to thesheave, a length of cable, hose or umbilical connection deployed, orboth. The sensors may be, for example, a load cell or a position sensor.The sheave may be coupled to an electronic control unit of the reelassembly, and the electronic control unit may receive informationindicative of either the determined force, the length of cable, hose orumbilical connection deployed, or both. The electronic control also maydisplay either a line tension value, a deployed cable value, or both,based on the received information.

In other various aspects, a reel assembly may include a plurality ofuser accounts having associated control permissions.

In other various aspects, a reel assembly may store a log of user inputsand information received from various sensors.

In yet another aspect, a reel assembly may include a user interface forsetting an alarm value which may notify a user when the value isexceeded.

In another aspect, a reel assembly may provide for the automatic controlof the reel by measuring system parameter(s), such as the tension of thecable, hose or umbilical connection, and automatically adjusting thebehavior of the system based on the measured parameter(s).

In other aspects, a retrofit kit for a pneumatically controlled hosereel assembly may include an electronic remote control unit forcontrolling one or more reel assemblies, one or more local control unitsfor controlling one or more reel assemblies, one or more sets ofelectro-pneumatic valves for operatively coupling the pneumatic driveunit of the reel assembly to either the local or remote control unit ofone reel assembly, and a sheave comprising a load cell and rotaryencoder for redirecting the direction of laid cable, hose, or umbilicalconnection and for measuring the line tension and deployed length ofcable, hose, or umbilical connection, wherein the sheave is operablycoupled to the local control unit, remote control unit, or both totransmit the measured line tension and deployed length.

Other systems, methods, features and technical advantages of theinvention will be, or will become apparent to one with skill in the art,upon examination of the figures and detailed description. It is intendedthat all such additional systems, methods, features and technicaladvantages be included within this summary and be protected by theclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention can be better understood with reference to the followingdrawings and description. The components in the figures are notnecessarily to scale, emphasis instead being placed upon illustratingthe principles of the invention.

FIGS. 1a-b show exemplary configurations of reel assemblies havingelectronic control systems on a drilling rig;

FIG. 2 shows a perspective view of an exemplary cable/hose reel assemblyhaving an electronic control;

FIG. 3 shows a front view of the cable/hose reel assembly of FIG. 2;

FIG. 4 shows a right side view of the cable reel assembly of FIG. 2;

FIG. 5 shows an exemplary local control panel for the cable/hose reelassembly of FIG. 2;

FIG. 6 shows a schematic diagram illustrating the operation of anexemplary electro-pneumatic drive system for use in an electroniccontrol system for a cable/hose spooling system;

FIG. 7 shows an exemplary remote control panel for the configuration ofcable reel assemblies shown in FIG. 1; and

FIG. 8 shows an exemplary turn down sheave for use with a cable/hosereel assembly shown in FIG. 2.

FIG. 9 shows another image of an exemplary turn down sheave for use witha cable/hose reel assembly shown in FIG. 2.

FIG. 10 shows an image of an exemplary remote control unit for use witha cable/hose reel assembly shown in FIG. 2.

FIG. 11 shows an image of the back of an exemplary electro-pneumaticenclosure for use with a cable/hose reel assembly shown in FIG. 2.

FIGS. 12a-b show images of exemplary reel control screens for a userinterfaces for remote and local control units for use with a cable/hosereel assembly shown in FIG. 2.

FIGS. 13a-b show images of exemplary alarm screens for the userinterfaces for remote and local control units for use with a cable/hosereel assembly shown in FIG. 2.

FIGS. 14a-b show images of exemplary configuration screens for remoteand local control units for use with a cable/hose reel assembly shown inFIG. 2.

FIGS. 15a-b show images of exemplary support screen on the userinterface for remote and local control units for use with a cable/hosereel assembly shown in FIG. 2.

FIG. 16 shows an image of exemplary administrative configuration screensfor a remote control unit for use with a cable/hose reel assembly shownin FIG. 2.

FIGS. 17a-b show images of exemplary control screens for remote andlocal control units for use with a cable/hose reel assembly shown inFIG. 2.

FIG. 18 shows another image of an exemplary control screen for anotherembodiment of remote control unit for use with the cable/hose reelassembly shown in FIG. 2.

FIG. 19 shows an image of an exemplary administrator control screen of aremote control unit for use with the cable/hose reel assembly shown inFIG. 2.

FIG. 20 shows an image of an exemplary factory/default settings screenof a remote control unit for use with the cable/hose reel assembly shownin FIG. 2.

FIG. 21 shows an exemplary data log.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The elements illustrated in the figures interoperate as explained inmore detail below. Before setting forth the detailed explanation,however, it is noted that all of the discussion below, regardless of theparticular implementation being described, is exemplary in nature,rather than limiting.

1.0 System Overview

Referring to FIGS. 1a-b , exemplary configurations of cable/hose reelassemblies 10 a-d are shown. Although the terms “cable,” “hose,”“umbilical,” and “cable/hose” are used to describe various aspects ofthe embodiments described herein, it should be understood by one ofordinary skill in the art that the embodiments may be used incombination with cables, hoses, umbilical connections and the like andthat use of the terms is exemplary in nature and not limiting. Asillustrated, the configuration includes four reel assemblies 10 a-doperating in conjunction with associated turn-down sheaves 500 a-d toprovide various cables, hoses and the like to a BOP stack 1050. Eachreel assembly 10 a-d may include an electronic local control unit 300(FIG. 2) and may also be connected to an electronic remote control unit400.

The cable/hose reel assembly 10 is shown generally in FIGS. 2-4, and maycomprise a spool assembly 11 powered by an electro-pneumatic drivesystem 200 operated via an electronic control unit 300. In someembodiments, the assembly 10 may include a plurality of electroniccontrol units 300, such as one or more local control units housed on thereel assembly 10 and one or more remote control units that may bephysically separate from the reel assembly 10.

1.1 Exemplary Reel Assemblies 10

The reel assembly 10 may comprise a frame 12 that rotatably supports acable spool 60 via drum supporting members 34, the spool 60 having acore or hub 62 and opposite end flanges 63. A cable, wire, hose, etc. isguided onto and off of the spool for even wrapping by means of a guideor “level wind” assembly 64 having a carriage 65 mounted for traversinga reversible diamond groove shaft 66 by means of a follower 68, as theshaft 66 is rotated. In some embodiments, the “level wind” assembly 64may operate like one or more of the ones described in U.S. Pat. Nos.7,210,647 and 8,061,644, each of which is incorporated by reference asif fully restated herein. Other “level wind” assemblies may be used.

Spool 60 may have a diameter between about 30 inches (nominally, about75 centimeters) and about 120 inches (nominally, about 30 centimeters)or more, preferably between about 48 inches (nominally, about 120centimeters) and about 72 inches (nominally, about 185 centimeters), andmay have a width between about 50 inches (nominally, about 125centimeters) and about 150 inches, and preferably between about 72inches and about 120 inches (nominally, about 300 centimeters). Theflanges 63 may have a diameter between about 48 inches (nominally, about120 centimeters) and about 205 inches (nominally, about 525centimeters), preferably between about 60 (nominally, about 150centimeters) inches and about 180 inches (nominally, about 460centimeters). The cable/hose may have a length between about 4,000 feet(nominally, about 1,200 meters) and about 20,000 feet (nominally, about6,100 meters), preferably between about 7,000 feet (nominally, about2,100 meters) and about 15,000 feet (nominally, about 4,600 meters) andeven more preferably between about 11,000 feet (nominally, about 3,300meters) and about 13,000 feet (nominally, about 4,000 meters). Anexemplary cable may have a diameter between about ½ of an inch(nominally, about 1.2 centimeters) and about 2½ inches (nominally, about6 centimeters), and typically about between about 1¼ inches (nominally,about 3.5 centimeters) and about 1¾ (nominally, about 4.5 centimeters).An exemplary hose may have a diameter between about 1½ inches(nominally, about 3.8 centimeters) and about 2½ inches (nominally, about6 centimeters), and an exemplary umbilical connection may have adiameter between about 4 inches (nominally, about 10 centimeters) andabout 8 inches (nominally, about 20 centimeters). Other sizes may alsobe used.

1.2 Exemplary Reel Assembly Frames 12

Frame 12 may include a plurality of vertical end frame members 14,horizontal end frame members 16, and cross members 18. Frame 12 also mayinclude a plurality of corner braces 20, such as braces 20 connectingvertical end members 14 to horizontal end members 16 or to cross members18.

Frame 12 further may include one or more intermediate, horizontal braces22, preferably a plurality of braces 22, around a perimeter of frame 12.Horizontal braces 22 may be located proximate a height of thecenter/axis of rotation of spool 60, preferably slightly below center ofspool 60.

2.0 Exemplary Local Control Systems 300

The electronic control system 300 may receive input from an operator tocontrol various aspects of the operation of the reel 11. In someembodiments, the electronic control system 300 may include aprogrammable logic controller (PLC) coupled to a touchscreen fordisplaying various interface controls, receiving user input anddisplaying status information to an operator. The PLC may be programmedto provide electrical signals to the electro-pneumatic drive unit 200 tocontrol the operation of the reel assembly as described below. Otherelectronic input devices, such as keyboards, keypads, and the like maybe used. Similarly, other components may be used to process the receivedinputs and provide control signals to the electro-pneumatic drive unit200, such as a stand-alone computer, and/or to display statusinformation to the operator, such as displays, LEDs and the like. Insome embodiments, the control unit 300 may include aproportional-integral-derivative controller (PID controller or threeterm controller) 345 that receives and/or processes input from a loadcell 502 of a turn down sheave 500, as described below. The electroniccontrol system 300 may be local control system that is fixedly and/orremovably attached to the frame 12.

2.1 Exemplary User Accounts

System 100 may include an electronic control system 300 with one or moreuser accounts in the system. For example, as shown in the Figures, anadministrative user may have access to all of the features of thesystem, such as reel control features (FIGS. 12a-b ), systemconfiguration settings (FIGS. 14a-b ), alert/alarm settings (FIGS. 13a-b), calibration settings (FIG. 16), and the like. These features may beaccessed through a touchscreen interface, such as the interfaces shownin FIGS. 12a-b . In the illustrated embodiment, reel control featuresmay be accessed via local interface control 362 and/or remote interfacecontrol 452, alarms features reel control features may be accessed vialocal interface control 364 and/or remote interface control 453,configuration control features may be accessed via local interfacecontrol 366 and/or remote interface control 454, support information 389(on local control 300 as shown in FIG. 15b ) and 489 (on remote control400 as shown in FIG. 15a ) may be accessed via local interface control368 and/or remote interface control 455, and administrativeconfiguration control/factory setting features may be accessed viaremote interface control 457

As another example, operator users may have access to limited featuresof the system, such as reel control features. Each user account mayinclude its own user profile and permissions. User accounts may beprotected by a password. In some embodiments, the system may require allusers to log into their user account before accessing the local (as seenin FIG. 12b ) or remote control unit 400 (as seen in FIG. 12a ) usingcorresponding interface controls 303 and 305 to log in or out,respectively. Alternatively, or additionally, some aspects of the systemmay be accessible without a password, e.g., guest access. The systemalso may time out certain or all users after a pre-determined period ofinactivity.

The electronic control system also may integrate with other controlsystems on a drilling rig, such as the driller's console or tool pusherpanel. This may allow the reel assembly to be controlled by other usersand/or from other parts of a drilling rig.

The system may include different types of users, such as administrativeusers, operator users, or operating group users. Other types of usersalso may be provided. An administrative user account may have privilegesand access to features not available to other users. This may includepermissions in the electronic control system 300 to set certainoperational limits for various parameters of the system (FIGS. 14a-b ).These parameters may include, among others, deployment speed (viacontrols 385 and 386 of the local control unit 300 and/or controls 485 aand 486 a of the remote control unit 400), cable tension (via controls387 and 388 of the local control unit 300 and/or controls 487 a and 488a of the remote control unit 400), and/or pneumatic pressure (viacontrols 381, 382, 383 and 384 of the local control unit 300 and/orcontrols 481 a, 482 a, 483 a and 484 a of the remote control unit 400).For example, a user with administrative privileges may set a certainupper and lower limit for the deployment speed control for a reel, thuslimiting all users to those speeds, via interface controls 385 and 386on the local control unit 300 and/or interface controls 485 a and 486 aof the remote control unit 400. In the embodiment illustrated in FIGS.14a-b , the administrative user has set a minimum of 0 psi of pressurefor both normal and tensioning mode and a maximum of 45 psi for normalmode and 30 psi for tensioning mode. Other values may also be used.

Certain user accounts, such as an administrative user account, may haveaccess to calibration features that allow the user to calibrate variousaspects of the system. For example, as shown in FIG. 16, anadministrative user may be able to calibrate the load cell and/or rotaryencoder of the turn down sheave 500 (as shown in FIGS. 8 and 9) viainterface control 494 a and 492 a, respectively. A user with properpermissions may zero-out a parameter at any time. For example, afterdeploying a cable to the seafloor, an administrative user may zero-outthe deployment length to easily see any subsequent changes in deploymentlength. As shown in FIG. 20, the system may limit access to theadministrative control screen to the remote control unit only. Theadministrator also may configure the system to activate select reels viacontrol 491 a and the system may only display the controls for thoseactive reels. The system may show active reels and controls in adifferent color, such as green and may show inactive reels or controlsanother color, such as grey.

2.2 Exemplary Administrative Features

As seen in FIGS. 13a-b , administrative user accounts also may set alarmlimits for various parameters. These parameters may include, amongothers, high cable tension, emergency stops, or control system alarms,such as for failed hardware or lost connections. These alarm limits maybe high or low alarm limits. Upon reaching a set limit, the electroniccontrol system 300 may indicate the limit to a user by visual alertssuch as changing the color of the local or remote control unit screen,displaying a notification on a local or remote control unit screen, orflashing lights on a local or remote control unit screen operablycoupled to the system. A user may clear an alarm notification on acontrol unit screen by acknowledging an on-screen prompt after thetriggering event has been remedied. In some embodiments, the system mayallow any user to clear alarm notifications. Alternatively, anadministrative user may be required to clear an alert. Some alerts mayclear automatically as soon as the fault is corrected, i.e. without userinput into the electronic control system.

Exemplary alarms may include an input value out of range, an invalidinput, an inability to maintain an oscillation value for the PID, achange for a set point, invalid input format, output calculation error,cycle interruptions, invalid set point format, invalid manual inputformat, invalid output value forma, local emergency stop buttonactivation, remote emergency stop button activation, high tension fault,and the like. Other alarms also may be used.

In some embodiments, administrators may have access to afactory-settings or default option, as shown in FIG. 20. Similar to theoperational settings above, the factory-settings may be include upperand/or lower limits for various parameters of the system, such asdeployment speed (via controls 467 a and 468 a), cable tension,pneumatic pressure (via controls 463 a, 464 a, 465 a and 466 a), and thelike. In some embodiments, the factory-settings may not be editable byan administrator.

2.3 Exemplary Operational Features for Local Control Unit 300

Referring to FIG. 5, an exemplary local control unit 300 is shown. Inthe illustrated embodiment, the local control unit 300 includes atouchscreen device 301 for displaying various interface controls302-330, receiving user input via the interface controls 302-330 anddisplaying status information to an operator. For example, the localcontrol unit 300 may display a line tension value 344 and/or a length ofcable deployed 346 that may be measured by sensors, such as a load cellor a position sensor, mounted in a turn down sheave that receives thecable mounted on the reel assembly 11, as described below. The localcontrol unit 300 also may display indicia that indicates the selectionof a user interface control 302-330. For example, upon selection of a“reel-in” control 302, the local control unit 300 may modify the colorof the “reel-in” control 302 to indicate its selection by the userand/or to indicate that the reel is winding the cable, as describedbelow. Alternatively, or additionally, other indicia, such as addingdisplay items, removing displayed items, and the like, may be used toindicate the selection of a particular control 302-330.

In some embodiments, the local control unit 300 may also includepneumatic pressure gauges 340 and 342 that may indicate the varioussystem pressure settings as shown in FIGS. 5 and 11. For example, afirst pneumatic pressure gauge 340 may indicate the pneumatic pressurein a normal mode of operation and a second pneumatic pressure gage 342may indicate the pneumatic pressure in a tensioning mode of operation,as described below.

In one embodiment, the operation of the reel assembly 11 via the localcontrol unit 300 may be as follows. To reel up a cable, an operator mayselect the “reel in” interface control 302, which activates thecorresponding solenoid valve 80 which in turn causes the drive motor 100to rotate (as shown in FIG. 6). The motor 100 can be reversed byselecting the “reel out” interface control 304, to reverse spoolrotation for continuously and evenly feeding out cable. The speed atwhich the spool rotates may be adjusted by selecting the “reel speedincrease” interface control 306 or “reel speed decrease” interfacecontrol 308 to increase or decrease the rotational speed of the spool,respectively. Selection of the “reel stop” interface control 326 maycause rotation of the spool to be halted. Selection of the “emergencystop” interface control 330 may cut-off power to the entireelectro-pneumatic drive system 200, and selecting the “emergency stop”interface control again may reactivate the electro-pneumatic drivesystem 200. Alternatively, or additionally, one or more additionalcontrols may be provided to reactivate the electro-pneumatic drivesystem 200. In some embodiments, previously established settings, suchas a tension setting for a “normal” mode of operation and/or a“tensioning” mode of operation, may be saved when the “emergency stop”interface control 300 is activated. In other embodiments, one or moresettings may be reset by depression of the “emergency stop” interfacecontrol 330.

2.3.1 Exemplary Operational Modes

An operator may switch between a “normal” mode of operation and a“tensioning” mode of operation by selecting the “normal pressure mode”interface control 310 or “pressure tensioning mode” interface control316. In some embodiments, these modes may be referred to as the “manual”mode and “automatic” mode, respectively, as shown in FIGS. 17a-b . Theoperator may increase or decrease the amount of tension in each of thesemodes independently via interface controls 312 and 314 for the “normal”mode and interface controls 318 and 320 for the “tensioning” mode.

2.3.1.1 Exemplary Normal or Manual Operational Mode

The “normal” mode of operation may be used, for example, to spool acable, hose or the like onto a reel during setup. In a “normal” mode ofoperation, a static pressure may be applied to the line, such as betweenabout 10 pounds per square inch (PSI) (nominally, about 70 kiloPascals(kPa)) and about 145 PSI (nominally, about 1000 kPa), preferably betweenabout 30 PSI (nominally, about 200 kPa) and about 110 PSI (nominally,about 760 kPa), more preferably between about 50 PSI (nominally, about340 kPa) and about 90 PSI (nominally, about 620 kPa), and in oneembodiment about 70-80 PSI (nominally, between about 480 kPa and about550 kPa). The pressure may be selected to generate a predeterminedcable/hose line tension for the reel assembly 10. In the “normal” modeof operation, selection of the “reel in” and/or “reel-out” controls 302and 304 cause the assembly 10 to wind in or pay out the cable or hose.

2.3.1.2 Exemplary Tensioning or Automatic Operational Mode

In a “tensioning” mode of operation, the assembly 10 may maintain asubstantially constant tension on the cable/hose, for example, toprevent the cable/hose from being tangled on any structure in the moonpool area as the drillship moves with wave motions. In one embodiment,an operator may activate a tensioning mode of operation as follows.First, the operator may select the “reel-in” interface control 302 andmay set an appropriate speed with control 306 and 308. Next, theoperator selects the “pressure tensioning mode” control 316 and selectsan appropriate pressure, such as between about 10 PSI (nominally, about70 kPa) and about 145 PSI (nominally, about 1000 kPa), preferablybetween about 15 PSI (nominally, about 100 kPa) and about 75 PSI(nominally, about 520 kPa), even more preferably between about 25 PSI(nominally, about 170 kPa) and about 50 PSI (nominally, about 345 kPa),and in one embodiment about 30-40 PSI (nominally, about 200-275 kPa). Asthe BOP stack is deployed (via its own controls and/or gravity) the linetension changes because, for example, the relative positions of the BOPstack and the rig may have changed due to water movement. In response,the system may either wind in the cable/hose (as the reel is set to“reel-in”) or allows slippage (via regulator 72 shown in FIG. 6) asnecessary to maintain the selected tension. In addition, because theoperator is able to read the line tension 344 as measured by a sensor502 on the turn down sheave 500 (described below in FIG. 8), theoperator may be able to adjust the tension by selecting the appropriatecontrols 318 and 320 to fine tune the operation of the system.

In some embodiments, selection of a user interface control 302-330 maycause a series of operations to be performed. For example, selection ofthe “pressure tensioning mode” control 316 may select a “tensioning”mode to be activated and may also cause the drive motor 100 to rotate towind in the cable or hose. Other combinations of operations may also betriggered by selection of a single interface control 302-330.

An operator may toggle control of the system between a local controlunit 300 and a remote control unit 400 (described below with referenceto FIG. 7) by selecting either the “local reel control” interfacecontrol 322 or the “remote reel control” 324.

3.0 Exemplary Electro-Pneumatic Drives 200

Referring again to FIGS. 2-4, the electro-pneumatic drive system 200 mayreceive control signals from the local control unit 300 (and/or theremote control unit 400 described below) and, in response, may power thereel motor 100 to wind the cable on the spool 60 and run the level wind64, among other features described above.

FIG. 6 shows a schematic diagram of one embodiment of anelectro-pneumatic drive system 200. In one embodiment, this system 200comprises a pneumatic air supply that may supply 340 standard cubic feetper minute (SCFM) up to about 145 PSI (nominally, about 1000 kPa), andtypical up to about 120 PSI (nominally, about 830 kPa). Other volumetricflow rates and pressure values may be used. In the illustratedembodiment, the air supply may be connected to the electro-pneumaticdrive unit 200 through an air filter 70, air regulator 72 and airlubricator 74, which may comprise Norgren models F17-800 A3DA,R24-801-RGNA, and L17-800-MPDA, respectively. A control panel 75includes solenoid valves 80 and 84 and proportional pressure controlvalves 87, 88 and 89. The solenoid valve 80 may be provided forcontrolling the reel direction (i.e. “reel in” and “reel out”) and maycomprise a Versa series VGG-4304-316-XMFA. A similar solenoid valve 84may be provided for selecting system pressure and mode of operation maycomprise a Versa series VGG-4302-316-XMFA. The proportional pressurecontrol valve 87, which may be of the type Norgen VP5010PK411H00, mayfeed the air regulator 94 for speed regulation. An output of the airfilter 70 may be connected with the same line to solenoid valves 80 and84 and proportional pressure control valve 87.

The proportional pressure control valves 87, 88, and 89 may receive avariable input signal ranging from about 4 to about 20 mA and may outputa variable pressure from about 0 psi to about 140 psi.

The outlets of the solenoid valve 84 feed pilot inputs to proportionalpressure valves 88 and 89, thereby allowing an operator to selectbetween a “normal” pressure mode and a “tensioning” pressure mode asdescribed in more detail below. The output of these valves 88 and 89 arevariable as a function the pilot input and fed to the air regulator 72via a shuttle valve 90. The proportional pressure valves 88 and 89 maybe of the type Norgren VP5010K411H00, while the valve 90 may be a VersaSV-3-316.

The air motor 100 receives an air supply from an air valve 101, which inturn is supplied by the air relay valve 94 and has pilot inputs from thesolenoid valve 80. The valve 101, an integral part of air motor 100, hastwo outputs, each of which feeds one side of the air motor 100, in orderto drive the air motor, and therefore the spool, in both directions. Forthe larger diameter valve 101, as well as for air motor 100, whichdrives the spool 60, the silencers may be of the type Allied Witan#0383007, or #0383010.

The air motor 100 may drive the spool through a planetary reducer 130.The planetary reducer may be of the type Brevini #PWD3200/SF/144/00/R33.Planetary reducer 130 may be used to slow the speed of the output fromair motor 100. It also may increase the torque applied by air motor 100.

A disc brake caliper 120 for the motor 100 braking system may beinterconnected to the air control system by way of shuttle valve 92 anda quick exhaust valve 124, which may be of the type Versa #QE-3-316. Thebrake caliper 120 may be configured like a typical air brake, i.e. heldin the applied position by spring pressure (not shown) and air pressureis used to release the brake from engagement. In the illustratedembodiment, the air motor 100 is a radial piston motor, such as theFenner SPX #R33-X-XX-R1.

Appropriate ball valves, needle valves, air exhaust silencers andpressure gauges, as indicated schematically, may be interposed in thevarious interconnecting lines in the diagram of FIG. 6.

4.0 Exemplary Remote Control Units 400

Referring again to FIGS. 2-4, an electrical interface 350 may beprovided for attaching one or more remote control units 400. In oneembodiment, the electrical interface 350 may be a multi-pin electricalconnector such as an Amphenol Industrial Star-Line® series “ZP/ZR”connector or the like. In other embodiments, the remote-control may becoupled to the electro-pneumatic drive system 200 via a wirelessinterface, such as wireless local area network (WLAN) adaptor thatcomports to the Institute of Electrical and Electronics Engineers'(IEEE) 802.11 standards. Alternatively or additionally, other wirelesscommunication interfaces, such as Bluetooth or ZigBee interfaces, may beprovided.

Referring to FIG. 7, an exemplary remote control unit 400 is shown. Theremote control unit 400 may be substantially similar to the localcontrol unit 300 shown in FIG. 5. For example, each of the userinterface controls 302-330 and/or display controls 344 of the localcontrol unit 300 may be mirrored on the remote control unit 400 (labeledwith corresponding references numerals 402 a-430 a) and may operate asdescribed above for the local control unit 300. The remote control unit400 may connect with the electro-pneumatic control system 200 of FIG. 6by way of an electrical interface 350, which essentially parallels theoutputs of the local control unit 300.

The remote control unit may include a touchscreen interface to allow theoperator to enter control inputs, log into the electronic controlsystem, and view recorded data. The remote control screen may contain acomputer to convert user inputs into control outputs and process thedata received from the sensors on the sheave. The computer may run adesktop or mobile operating system, such as Microsoft® Windows®, or thelike. The remote control unit may include a stainless steel cover whichcan be placed over the touchscreen to protect the touchscreen fromdamage from water, oil, and/or other debris. The touchscreen may bemounted at about a 45 degree angle to make operating the screen easierfor the operator.

The remote stand may also include a camera 600 located above thetouchscreen as shown in FIG. 10. This camera 600 may take photos orvideo upon certain system events, such as when a user logs in, when acontrol input is made, or when the system activates an alarm. The remotecontrol unit 400 and/or PLC may store the photo or video with other datalogged from the system. The remote control unit 400 also may contain oneor more input/output cards which received information from the sheavesensors and outputs data to the PLC. The sheave may be designed andmanufactured to withstand a Class 1, Zone 1 classification based onthose created by the National Fire Protection Association (NFPA).

In the illustrated embodiment, the remote control unit 400 may include aseparate panel 460 for each reel assembly 10 coupled to the remotecontrol unit 400. In some embodiments, the panels 460 a-d may be colorcoded to indicate its corresponding reel assembly 10. Alternatively, oradditionally, other indicia, such as text labels, may be used toindicate the associated reel assembly 10.

Selection of an interface control on either the local control unit 300or the remote control unit 400 may cause indicia indicating theselection of the control and/or the currently selected mode of operationon the other control unit 300 and 400. For example, selection of the“reel-in” control 302 on the local control unit 300 of a reel assembly10 may cause indicia indicating that the reel is currently winding thecable or hose, just as if the operator had selected the “reel-in”control 402 on the remote control stand. Notably, an operator may togglecontrol to the remote control unit 400 by selecting the “remote reelcontrol” interface control for a given reel assembly 10. In response,indicia will be displayed on the local control unit 300 to indicate thatthe remote control unit 400 currently has control of the reel assembly10.

5.0 Exemplary Turn Down Sheaves 500

Referring to FIG. 8, an exemplary turn down sheave 500 for use in a reelassembly having one or more electronic control units 300 and 400 isshown. The sheave 500 may include a load cell 502 or other sensor thatmeasures a force applied at the sheave 500 relating to the cable/hosetension. Alternatively, or additionally, the sheave 500 may include aposition sensor 504 (such as a rotary encoder, reed sensor or the like)that measures the length of cable/hose that has been deployed (i.e. fedout to the BOP stack). In one embodiment, the sheave 500 may transmitthese measurements to the electro-pneumatic drive 200, which in turntransmits that information to the local control unit 300, the remotecontrol unit 400, or both. Alternatively, or additionally, the sheave500 may be directly coupled to the local control unit 300, the remotecontrol unit 400, or both. In either case, the information received fromthe sensors 502 and 504 on the sheave may be directly displayed on thecontrol unit 300, such as at interface controls 344 and 346, or may bemathematically manipulated, reformatted, or the like in order to bedisplayed on the control unit 300.

The sheave 500 shown in FIGS. 8 and 9 may have a plurality of rollers506 to redirect and guide the cable, hose, or umbilical. The sheave 500may have about three rollers 506 to about twelve rollers 506 andpreferably about six rollers 506. Rollers 506 may be shaped to centerthe cable, hose, or umbilical in the center of the roller 506, such as a“U” cross-sectional shape. The operator may set up the sheave 500 usingone or more rollers 506 to redirect the cable, hose, or umbilical atvarious angles ranging from about 10 degrees to about 180 degrees. Thesheave also may include a tensioner to maintain contact between thecable, hose, or umbilical and the rotary encoder 504 to ensure thesensor accurately detects all movement of the cable, hose or umbilical.The tensioner may be adjusted by using a threaded screw to adjust thepressure of the tensioner on the cable, hose, or umbilical. Furthermore,the sheave may include one or more latches which fold over the sheave500 and hold the cable, hose, or umbilical on the sheave rollers 506.The rollers 506 may be made from nylon or other polymers. Each roller506 may be mounted to the sheave using a bolt which may be made fromstainless steel.

The sheave 500 may measure the cable tension by using a load cell 502.The load cell 502 may be removably attached to the top of the sheave 500and to a shackle for attachment to another cable or roof of the moonpool. The load cell 502 may output an analog signal to an enclosure onthe sheave 500 which may contain a signal conditioner and one or moreisolation barriers. Those devices may prepare the signal from the loadcell 502 and rotary encoder 504 and send the signal to the local controlunit 300 and/or remote control unit 400. The local control unit 300and/or remote control unit 400 may convert the signal to a digitalsignal and may then send the digital signal to the PLC where it may bestored.

The sheave 500 also may have a rotary encoder 504 to measure thedeployed length of cable, hose, or umbilical. The rotary encoder 504 maysend an analog signal through the enclosure on the sheave 500 which maycontain a signal conditioner and one or more isolation barriers. Therotary encoder 504 may be attached to a roller 506 which engages withthe cable, hose, or umbilical and may have a diameter of about 1 inch.After sending the signal to the enclosure, the signal is sent to thelocal control unit 300 and/or remote control unit 400 where the signalmay be converted to a digital signal, and then may be sent to the PLCwhere the signal may be converted to a linear length of deployed cableand displayed on the local or remote control stand. The PLC also maystore the length of deployed cable.

5.1 Exemplary Automatic Control Based on Measured Parameters

In another embodiment of the “tensioning” or “automatic” mode ofoperation, the assembly 10 may maintain a substantially constant tensionon the cable/hose by measuring one or more system parameters andautomatically adjusting the behavior of the system 10 based on themeasure parameter(s). For example, an operator may activate a tensioningmode of operation by setting a target tension via the “tension”interface controls 360 and selecting the “reel-in” control 302.Exemplary tensions may be between about 100 pounds and about 1000pounds, preferably between about 200 pounds and about 600 pounds, evenmore preferably between about 250 pounds and about 500 pounds, and insome embodiments between about 300-400 pounds. In response, the systemmay wind in the cable/hose (as the reel is set to “reel-in”) asnecessary to maintain the selected tension.

As the BOP stack is deployed (via its own controls and/or gravity) theline tension changes because, for example, the relative positions of theBOP stack and the rig may have changed due to water movement. Thiscondition may be detected, for example, by measuring line tension withload cell 502, which may transmit its output signal to aproportional-integral-derivative controller (PID controller or threeterm controller) 345 (FIG. 3). Because the system is able to monitor theline tension 344 as measured by the load cell 502 sensor on the turndown sheave 500, the system 10 may be able to automatically adjust thetension by transmitting appropriate control signals to the PLC. Forexample, when the PID controller 345 detects that the tension 344exceeds the target value, the PID controller may operate with an outputof zero until the tension is lower than the set point. Otherwise, if thetension is below the target tension, the PID controller may continue to“reel-in” the cable, hose or umbilical.

In some embodiments, the system 10 may allow the tension 344 to varyfrom the target tension within a predetermined limit before action istaken. For example, the system 10 may allow the tension 344 to exceedthe target value by a predetermined percentage before action is taken.Exemplary percentages may include between about 5% and about 30%,preferably between about 10% and about 20%, and in some embodimentsabout 15%. Alternatively, or additionally, limits may be based onpredetermined increments, such as 5 pounds, 10 pounds, 25 pounds, 50pounds, 100 pounds, and the like.

The sheave 500 may be designed and manufactured to Det Norske Veritas(DNV) and/or American Bureau of Shipping (ABS) lifting standards. Thesheave may also be designed and manufactured to adhere to the Class I,Zone 1 NFPA classification. The sheave 500 may be designed withdifferent bend radii, ranging from about a 20 inch bend radius to abouta 34 inch bend radius, and preferably about a 24 inch bend radius.

6.0 Exemplary Data Logging Features

The system 10 also may log data for creating and storing a record of theuse of the system 10. In some embodiments, the system 10 may generate atransaction log of every input entered into the system 10 and each pieceof data collected by the system 10 itself. Alternatively, oradditionally, subsets of inputs and collected data may be logged. In oneembodiment, the system 10 may log the following information for eachinput: the user account logged in at the time of the received input, theselected input (e.g., reel speed increase, tension setting adjustment,etc.), the new value of the set point, the previous value of the setpoint, and a time/date stamp. The system 10 also may log each controlinput data with a reason for the input as entered by the user. Thesystem 10 also may log every instance of an alarm limit triggering, suchas the initial triggering of the alarm and/or the clearing of the alarm.More or less information may be logged.

Furthermore, the system 10 may periodically sample data from varioussensors, such as the load cell 502 or rotary encoder 504 on the sheave500, and record and store the data. The data logged may include allsystem inputs and outputs, the system state, alarm conditions,calculated variables such as cable payout, and the like. The data may beperiodically sampled at various periods. These data sampling periods mayrange from once per about 1 second to about 1 minute, preferably about 5seconds to about 30 seconds, and most preferably about 10 seconds. Insome embodiments, data may be recorded and stored whenever the system 10also logs a control input or when an alarm limit is triggered.

An exemplary data log 2100 is shown in FIG. 21. In the illustratedembodiment, the system 10 may record a pressure set point(s), a speedset point(s), line tension(s), system mode (e.g. manual or automatic),reel in settings, reel out settings, stop inputs, remote/local controlsettings, and the deployed length of the cable, hose or umbilicalconnection. For each entry in the log 2100, the system 10 may record avariable name (“VarName”) 2112, the time the data was logged(“TimeString”) 2114, the value of the variable (“VarValue”) 2116, anindicator of the functioning of the system 10 (“Validity”) 2118, and therecorded time of the variable change in the system (“Time_ms”) 2120, thetitle of which may be included in the first line 2110 of the log 2100.For example, the first recorded entry 2130 a in the illustrated log 2100indicates that the value of “0” (2136 a) was recorded for the variable“dbGlobal_HMI_Control_RiserFill.RealVars.Speed_Act” (2832 a) at“2017-08-18 10:22:19” (2134 a) while the system 10 was functioning instate “1” (2138 a) indicating a valid connection between the to the PLC(as opposed to a zero entry that indicates no connection between thetwo). The entry 2130 a also indicates that the system time was“42965432167.8241” (2140 a) when this variable 2132 a was changed to therecorded value 2136 a. More or less information may be stored in thelogs 2100.

Recorded data may be accessed via the local control unit 300, the remotecontrol unit 400, or both. For example, a download option may beprovided via a screen accessible to an administrative account user. Thedata may be stored locally using means such as a hard drive, solid statememory, or the like. In addition, the data also may be stored remotely,such as on a remote server computer, network attached storage, or thelike. The data may be exported using a network connection, such as overa wired or wireless local area network using a wireless access point orEthernet port. Furthermore, the data may be exported using a computerport attached to a control unit, such as a universal serial bus (USB)port, IEEE 1394 port, or the like.

FIG. 11 shows an enclosure which may be used on a reel assembly 10. Thisenclosure may contain the PLC and power supply for the reel assembly.The enclosure may include a plurality of bolt holes to further anchorthe enclosure lid shut. The enclosure may include a power toggle switch332 and an emergency kill switch 330. When the emergency kill switch 330is activated, the system may interrupt any control signal and may purgethe solenoid and/or proportional valves of air which may cause the reelassembly to stop.

Unlike purely pneumatic systems that suffer performance inherentlimitations such as degradation over long distances, use of the localand remote electronic control units 300 and 400 in cooperation with anelectro-pneumatic drive unit 200 as described herein virtuallyeliminates any loss in system response time and enables a reel operatorto control the system 10 from any location on the drilling rig.Alternatively, or additionally, the systems and methods described hereinalso may enable a “driller's console” to be established where the BOPstack deployment may be observed via a series of cameras and theoperator may manipulate the system via a remote electronic control unit400 and even select control of a particular reel assembly 10 directlyfrom the remote stand.

7.0 Exemplary Retrofit Kit

A kit may be provided for retrofitting certain above disclosed featuresto other reel systems, such as pneumatic reel systems. These systems maylack electro-mechanical control systems, a remote control unit, or otherfeatures disclosed herein. For example, the kit may include a localcontrol touchscreen, remote control unit, sheaves with load cells androtary encoders or other sensors, and a plurality of electro-pneumaticcontrol valves and solenoid valves for connecting to an existingpneumatic control system. In one embodiment, the kit also may include atouch screen for the local control unit, 2 electronics enclosures for acontroller and for the control valves, two solenoid valves, and threeelectro-pneumatic proportional valves. The solenoid valves may be thesame as valves 80 and 84 described above and shown in FIG. 6.Furthermore, the electro-pneumatic proportional valves may be the sameas valves 87, 88, and 89 as described above and shown in FIG. 6. Thecontroller may comprise a programmable logic controller (PLC) and apower supply. The kit also may include one or more brackets for mountingthe enclosures to the reel assembly. These brackets may be made fromassembled angle iron. The kit also may include all necessary wiring,mounts, cables, fasteners, and other hardware required to install thecomponents of the kit.

While various embodiments of the invention have been described, it willbe apparent to those of ordinary skill in the art that many moreembodiments and implementations are possible within the scope of theinvention. Accordingly, the invention is not to be restricted except inlight of the attached claims and their equivalents.

I claim:
 1. A reel assembly for accepting, holding, and deploying cable, hose, umbilical connection or the like, comprising: a spool assembly including a frame and a drum mounted in said frame, the drum including a core and end flanges for storing said cable, hose or umbilical connection; an air motor; an electro-pneumatic drive unit including a plurality of pneumatic valves, electro-pneumatic valves, or both, the air motor coupled to the drum via the electro-pneumatic drive unit; an electronic control unit coupled to the electro-pneumatic drive unit, where the electronic control unit receives a first input from a digital input device and transmits electrical signals to the electro-pneumatic drive unit to cause the electro-pneumatic drive unit to control the motor to rotate the drum, where the electronic control unit receives a second input and transmits electrical signals to the electro-pneumatic drive unit to cause the electro-pneumatic drive unit to increase or decrease an air pressure associated with the assembly.
 2. The reel assembly of claim 1, where the digital input device includes a touchscreen.
 3. The reel assembly of claim 1, where the electronic control unit is fixedly attached to the frame.
 4. The reel assembly of claim 1, where the electronic control unit displays status information.
 5. The reel assembly of claim 4 further comprising a sheave coupled to one or more sensors that determine either a force applied to the sheave, a length of cable, hose or umbilical connection deployed, or both.
 6. The reel assembly of claim 5, where the sheave is coupled to the electronic control unit, the electronic control unit receives information indicative of either the determined force, the length of cable, hose or umbilical connection deployed, or both.
 7. The reel assembly of claim 6, where the electronic control unit displays either a line tension value, a deployed cable, hose or umbilical connection length value, or both, based on the received information.
 8. The reel assembly of claim 6, where the electronic control unit stores a log of the received information.
 9. The reel assembly of claim 6, where the control unit controls the operation of the reel based on the received information.
 10. The reel assembly of claim 6, where the control unit includes a PID controller that processes the received information and controls the operation of the reel when the received information exceeds a predetermined target value.
 11. The reel assembly of claim 6, wherein the electronic control unit provides user interface controls for setting an alarm value for the received information and notifies a user when the preset alarm value is exceeded.
 12. The reel assembly of claim 1, where the electronic control unit includes a plurality of user accounts having associated control permissions.
 13. The reel assembly of claim 1, where the electronic control unit stores a log of received user inputs.
 14. A retrofit kit for a pneumatically controlled reel assembly for accepting, holding, and deploying cable, hose, umbilical connections or the like, including a reel and a pneumatic drive unit for rotating the wheel, the kit comprising: an electronic remote control unit for controlling one or more reel assemblies; one or more local control units for controlling each of one or more reel assemblies; one or more sets of electro-pneumatic valves for operatively coupling the pneumatic drive unit of the reel assembly to either the local or remote control unit of one reel assembly; and a sheave comprising a load cell and rotary encoder for redirecting the direction of laid cable, hose, or umbilical connection and for measuring the line tension and deployed length of cable, hose, or umbilical connection, wherein the sheave is operably coupled to the local control unit, remote control unit, or both to transmit the measured line tension and deployed length.
 15. The retrofit kit of claim 14, where the local control unit displays either a line tension value, a deployed cable, hose or umbilical connection value, or both, based on the received information.
 16. The retrofit kit of claim 14, where the local control unit controls the operation of the reel based on the received information.
 17. The retrofit kit of claim 14, where the remote control unit controls the operation of the reel based on the received information.
 18. The retrofit kit of claim 14, wherein the local control unit provides user interface controls for setting an alarm value for the received information and notifies a user when the preset alarm value is exceeded.
 19. The retrofit kit of claim 14, where the local control unit stores a log of the received information. 